Flocked products and their manufacture

ABSTRACT

Novel flocked products, their preparation and apparatus for use in their preparation are described. The products comprise a substrate with a surface of flocked fibres bonded to it by a hardened binder and the fibres over part of the surface have a predominant, non-perpendicular orientation and are substantially linear and over another part of the surface have a different, predominant, non-perpendicular orientation and are substantially linear. The products enable excellent design interest and resistance to use defects e.g. bruising to be readily achieved.

Jepson Nov. 4, 1975 FLOCKED PRODUCTS AND THEIR [56] References CitedMANUFACTURE UNITED STATES PATENTS [75] Inventor: Frank M. Jepson,Morecambe, 2,563,259 8/l951 Miller 117/9 England 3.l7|,484 3/1965Thal 1. 161/63 [73] Assigneei :airn j z Limited PrinuzryExaminer--Marion E. McCamish ancas ng an Attorney, Agenl, orFirmSughrue, Rothwell, Mion, [22] Filed; Sept. 28, 1973 Zinn & Macpeak21 A 1, N 401,790 1 pp 0 1571 ABSTRACT Novel flocked products, theirpreparation and appara- [30] Foreign Apphcatlon Priority Data tus foruse in their preparation are described. The Oct. 3, 1972 United Kingdom4. 45588/72 pmduas comprise a Substrate with a Surface f flocked fibresbonded to it by a hardened binder and [52] U.S. Cl. 427/198; 118/308,156/72; the fibres Over part of the surface have a predominant 156/ 435;427/200; 427/206; 428/88; 428 non-perpendicular orientation and aresubstantially [51] 3 D031) 27/00; DO4H 1 1/00 linear and over anotherpart of the surface have a dif- [58] Fleld of Search 161/62-67, ferempredominant, nomperpendicular Orientation 161/413; 156/622,62.4, 72,435:117/9, 16, 117/104 R, 93.4 R, 101,33; 118/308165/8: 264/8, 143, 24, 95,131; 26/2 R, 69 R, 27,

1 -".Jlllll111l and are substantially linearv The products enableexcellent design interest and resistance to use defects e.g, bruising tobe readily achieved.

9 Claims, 3 Drawing Figures FLOCKED PRODUCTS AND THEIR MANUFACTURE Thisinvention relates to flocked products.

In general flocked products comprise a substrate the surface of whichcarries a very high density of flocked fibres that are usually bothshort in length and of fine denier and that are bonded to the substrateby a bond ing agent applied to the substrate. Thus they are gener allymade by flocking fibres onto a substrate carrying an unhardened adhesiveand then hardening the adhe sive. They find application as, for example,upholstery materials, garment materials, shoe materials, carpets andartificial suedes.

Flocked products in general have a velvet-like or suede-like feel andappearance and in particular generally have the characteristic sheen ofmany suedes and velvets.

When the flocking is effected by electrostatic means the flocked fibresare oriented substantially vertically with respect to the substrate,because of the influence ofthe electrostatic field. Any deviations fromthe vertical are random; that is to say, there is no predominantorientation of the fibres other than perpendicular to the substrate. Infact, if precision cut flock is used, there is usually very littledeviation from the perpendicular. When flocking is by mechanicalmethods, the fibres tend to have a slightly more random orientation, butagain there is no predominant orientation other than vertical.

Overall flocked products are therefore usually very uniform and plainand therefore lack design interest. Since the predominant orientation ofthe fibres is substantially vertical, the application of pressure ontothe fibres during use results in flattening. This flattening isextremely noticeable when compared to the sheen of the new product,especially since the random deflection of the fibres may cause theproduct to appear to be of variable colour. It is conveniently termedbruising.

Design interest has been imparted to these flocked products bysoftening, usually by heating, the adhesive and then embossing with anembossing roller to form a stripe or zig-zag pattern of embossed areasseparated by areas in which the fibres retain their substantiallyperpendicular orientation. Such a method has been described in, e.g.,British patent specification No. 717161. However, in the embossed areasthe flattening of the fibres tended to have a significant randomcomponent, and so the appearance in the embossed areas is not entirelysatisfactory. Also, the appearance is liable to be damaged by somedegree of bruising during use. Also the fibres in the embossed areas arenon-linear; that is to say, the individual fibres are bent with the tipsbeing deflected considerably more than the bases of the fibres. Againthis tends to detract from the appearance and to render fabric liable toacquire a bruised appearance. Furthermore, embossing techniquesgenerally only enable surface effects of rather limited design interestto be achieved.

A flocked product according to the invention comprises a substrate and asurface of flocked fibres bonded to it by a hardened binder. The fibresover part of the surface area of the product are substantially lin earand have a predominant, non-perpendicular orientation and over anotherpart of the surface area the fibres are substantially linear and have adifferent, predominant, non-perpendicular orientation. The products havea velvet-like or suedelike appearance. Fibres in one or more areas willhave one predominant, nonperpendicular orientation, while fibres in oneor more other areas will have a different, predominant,non-perpendicular orientation. Thus products according to the inventiondiffer from products made by embossing methods.

In the products of the invention there will often be only two different,predominant, non-perpendicular orientations and, whilst there may beonly two distinct areas in which these orientations are found, usuallyat least one of the orientations will apply in two or more distinctareas. However, there may be three or more different, predominant,nonperpendicular orientations in a case where there are three or moredistinct areas having a predominant, non-perpendicular orientation.Often the entire surface will be composed of areas having a predominant,non-perpendicular orientation but one or more areas having apredominant, perpendicular orientation and/or one or more areas having aran dom orientation may also be present.

The product of the invention is best made by a method in which thefibres are flocked onto a substrate carrying a fluid binder; the fibresare laid in part of the surface area with a predominant,non-perpendicular orientation and in another part with a different,predominant, non-perpendicular orientation and the binder is thenhardened.

As a result, upon laying the fibres down, the fibres lay downsubstantially along their entire length, and are therefore substantiallylinear, whereas in embossing methods the deflection of the tips of thefibres is significantly greater than the deflection of the bases of thefibres. Also, as a result of the method of the invention, the fibreswithin each individual area have a more predominant orientation, i.e.are less randomly laid, than in embossed products. In general, theproducts of the invention have a much more pleasing appearance thanflocked products that have been made previously and in particular havean appearance that is more resistant to bruising and other use defects.

The orientation of fibres within an area of the surface is usually suchthat substantially all the fibres in the area of the surface liesubstantially all in one direction along the surface, for example at anangle of less than 45 and usually less than 30, for example 10 to 20, tothe plane of the surface.

By the invention it is possible to produce a wide range of designeffects in the surface, by suitable choice of orientations in flattenedareas and optionally also by the inclusion of unflattened areas. Theflattened areas have the particular advantage that their appearance isnot harmed by wear and so it is generally preferred that the entiresurface of the fabric should have its fibres laid in two or morepredominant, non-perpendicular, orientations.

The individual areas of fibres having a predominent orientation may bearranged in any desired pattern which may be, for example, a regular orgeometric pattern, or it may be one that gives the appearance of beingan irregular pattern, for example a marble effect.

Various methods of laying the fibres of the flock can be used andinclude the use of bars or combs against which the flock can be made tomove, for example by moving the substrate beneath the bars or combs, orair jets. However particularly satisfactory methods involve simplemechanical rolling or brushing. Conveniently the apparatus used includesmeans such that the de- 3 sired pattern of different orientations indifferent areas is achieved in one operation. although if desired theflocked product can of course be subjected to two or more pressing orbrushing processes to achieve the desired pattern.

If fibres are to have orientations in stripes that extend along thelength of the fabrics, then these orientations can adequately beaccomplished by passing the flocked substrate beneath brushes, rolls orother members that, in combination with the movement of the substraterelative to the member, cause the fibres to be deflected in the desireddirections. If the fibres before orientation have a very randomorientation, then it may be desirable to rely upon brushing rather thansimple rolling to achieve the desired predominant orientations.

For any other arrangement of areas, it is necessary to use an apparatusthat is designed to provide the necessary pressing or brushing effect inthe appropriate areas to give the chosen pattern.

A simple form of apparatus for producing a pattern of areas having onepredominant non-perpendicular orientation and areas having a differentpredominant non-perpendicular orientation comprises a stencil (ie aperforated band or roller) and means in the stencil capable of orientingseparately fibres in areas corresponding to the apertures of thestencil. There should be no relative movement at the zone of contactbetween the stencil and the surface so that all fibres contacted by thesolid areas of the stencil are oriented in one direction while thefibres in areas corresponding to the perforations will be orientedindependently, usually in a direction parallel but opposite to thedirection of the other fibres. As an example, if the fibres contacted bythe solid areas of the stencil are oriented such that they inclinetoward the north in a given rug lieing in a given position, the fibresin areas corresponding to the perforations in the stencil are orientedsuch that they incline toward the south. Alternatively, all the fibresin the surface may be deflected in one direction by brush ing or othermeans, but then fibres in parts only of the surface may be reoriented bythe orienting means within the stencil.

Conveniently the orienting means comprise brush bristles that may bemoved relative to the stencil. For example a cylindrical brush may bemounted coaxially with the stencil for rotation independent of thestencil and may have its bristles extending almost to or into theapertures of the stencil. Normally brush bristles or other orientingmeans in the stencil do not extend out through the apertures, at leastto any significant extent, but bring about orientation only of fibresthat extend into the apertures. Suitable brush bristles are usuallyfairly soft, for example having characteristics similar to those of aconventional personal hairbrush.

When some or all of the laying of the fibres is brought about by meansof stencils, the pressure between the stencil and the product beingtreated is generally very low. Thus the roller or stencil is normallypositioned so as to contact only those parts of the fibres that extendabove the adhesive carried on the substrate, and, for the production ofproducts of optimum appearance, it is essential to ensure that thestencil does not squeeze the adhesive with the result that the entirelength of the flocked fibres would become embedded within the adhesiveand the fine pile desired on the product would be destroyed. In anymethod of the invention, the laying conditions should be such that thefibres do not to 4 any substantial extent become further embedded in theadhesive.

Any suitable substrate may be used in the invention. Preferably thesubstrate is of fibrous material. i.e., is a textile or paper substrate,as such substrates are generally more suitable than continuous plasticsfilms. Examples of suitable substrates are woven, knitted and non wovenfabrics made from natural or synthetic fibres, and also paper.

Binders that can be used include any suitable flocking adhesives.Examples are acrylic binders. vinyl chloride homopolymer or copolymerplastisols and polyurethane binders. Generally they are binders that canbe applied from solution or dispersion in very fluid form and can thenbe solidified by heating at moderate temperatures, for example below C,the solidification either being brought about solely by evaporation ofsolvent or dispersant or being brought about also by crosslinking orother chemical curing or other means.

Fibres that can be flocked include cotton, rayon, nylon, acrylic andpolyester fibres. They can be precision cut fibres or ground fibres ormixtures thereof. They can be applied by any suitable method offlocking, for example electrostatic flocking or by mechanical flocking.Typical fibre lengths are 0.1 to 5 mm, preferably 0.3 to 3 mm, mostpreferably below l.5 mm. Typical deniers are 0.3 to 30 denier,preferably 0.5 to 20 denier. As is customary in flocked products of thegeneral type to which the invention relates, the fibre density isusually high-cg. 10 to 15% of the theoretical maximum for close packedcylinders.

In the accompanying drawings,

FIG. 1 illustrates in side view diagrammatically an apparatus being usedfor carrying out the method of the invention,

FIG. 2 is a plan view of the roller illustrated in FIG. I, and

FIG. 3 is a longitudinal cross section ofa product according to theinvention, for example obtainable by apparatus similar to that shown inFIGS. 1 and 2.

The apparatus in FIG. 1 comprises a hollow cylinder 1 made of thin sheetmaterial, for example metal, mounted on a central shaft 2. The surfaceof the cylin der has a number of apertures 3 cut in it so that thecylinder is a stencil. Concentric with the cylinder and mounted on asleeve 4 over the central shaft 2 is a cylindrical soft brush 5. Thebristles of this brush are of such a length that they are approximatelyflush with the outside surface of the cylinder and thus protrude intothe apertures 3. The apparatus also includes means for rotating thebrush and the cylinder independently of one another. The cylinder 1 ismounted above a flat table 6 or any other suitable support, eg a roller.

Flocked material 7 (for example made by conventional electrostaticflocking) comprising a substrate 8 and fibres 9 substantially verticalto the substrate is led to between cylinder I and the table 6 directlyfrom the flocking operation, while the adhesive on the substrate 8 isstill wet. (The length of the fibres is greatly exaggerated in FIG. 1).The cylinder rotates in the direction of the arrow at such a speed thatits peripheral linear velocity is identical to that of the material 8 asthe material passes beneath it. As a result the cylinder presses thetips of the flock lightly in such a manner that the flock in all areasexcept in the apertures is laid in the direction opposite to thedirection of movement of the material by the surface of the cylinder.

Where there are apertures in the cylinder the flock would. in theabsence of the brush, retain its vertical orientation. However. in theprocess illustrated the brush 5 is provided and this is rotated at aconsiderably higher speed that the cylinder, but in the same directionas the cylinder, and this causes the flock in the positions of theapertures to be deflected in the direction of movement of the material.As a result the fabric leaving the cylinder has the fibres over themajority of the surface deflected in one direction while the fibres inthe areas corresponding to the apertures 3 are orientated in theopposite direction. On subsequent hardening of the adhesive, for exampleby curing in a suitable oven, the fibres are anchored in the providedorientations.

As shown in FIG. 3, the resultant product comprises a textile base 8carrying adhesive and fibres 9a oriented in one direction and fibres 9bparallel to these but oriented in the opposite direction. A typicalangle of orientation is to the plane of the surface.

A further process, for producing striped effects, involves the use of arotating brush which first lays all the flock in one direction. This isfollowed by a second brush operating through a fixed stencil, whichrotates in the opposite direction and reorientates alternate stripes ina direction opposite to the original lay of the flock. Alternatively,the second brush and stencil may be replaced by a suitably profiledbrush. A further method of producing striped effects involves the use ofcomplementary profiled brushes rotating in opposite directions.

The following are some examples.

EXAMPLE I A plain weave cotton cloth weighing about 5 ounces per squareyard is spread with a thickened, cross-linking acrylic adhesive (soldunder the trade name Primal HA8) at an application weight of about 10ounces per square yard (wet weight), i.e., 4 ounces per square yard dryweight. Precision cut nylon flock, of length 1 mm and denier 3, iselectrostatically deposited on the adhesive. The flocked material isthen passed through the apparatus illustrated at a rate of 6 feet perminute. The cylinder has a diameter of 6 inches and rotates with aperipheral velocity the same as the rate of movement of the fabric. Thebrush rotates at a peripheral velocity of 24 ft/min. The fabric is thenled through a curing oven for 5 minutes at l40C. The finished product issuitable for use as an upholstering material.

EXAMPLE 2 A plain weave cotton cloth weighing about 3% oz. per squareyard is spread with a thickened cross linking acrylic adhesive (soldunder the trade name Primal K87) at a wet application weight of about 10oz./sq. yd. (4 ounces per square yard dry weight). Precision cut rayonflock of length 0.5 mm and 0.5 denier is electrostatically deposited ata weight of 2 oz. per sq. yd. onto the adhesive. The flocked materialthen passes under a rotating profiled brush which lays part of theflocked surface in one direction and then under a complementary profiledbrush, rotating in the opposite direction to the first, which lays theremaining flock to give a striped effect. The fabric is led through acuring oven for 5 minutes at 140C. The finished products is suit ablefor use as a garment material.

EXAMPLE 3 A wallpaper base of weight 2% oz. per. sq. yd. is coated witha PVC plastisol adhesive at an application weight of approximately 3 oz.per sq. yd. Precision cut rayon flock of length 1 mm and 4% denier iselectrostatically deposited onto the adhesive at a weight of 2% oz. persq. yd. The flocked material is then passed through the apparatusillustrated in FIG. 1 under the conditions of Example 1. The material isthen passed through a curing oven for 3 minutes at C. The finishedproduct is suitable for use as a wall covering.

By similar methods a wide variety of flocked prod ucts can be made, forexample other upholstery cloths. or garment materials, carpets, shoematerials or curtain fabrics.

I claim:

1. A method of making a flocked product comprising a substrate havingbonded to its surface a layer of flocked fibres which are substantiallylinear and which, in different parts of the surface, have differentpredominant non-perpendicular orientations, said method comprising thesteps of:

a. applying fluid binder to the surface of the substrate;

b. flocking fibres onto the fluid binder;

c. laying the flocked fibres in a first part of the area of the surfacein a predominant non-perpendicular direction while maintaining themsubstantially linear by rolling a stencil having perforations in theperipheral surface thereof over and in contact with the product with norelative movement at the zone of contact between the stencil and theproduct;

d. laying the fibres in a second part of the area of the surface in adifferent predominant non-perpendicular orientation while maintainingthem substantially linear by movement of a separate movable orientationmeans contained in the stencil, the said second area being the area ofthe surface in contact with the perforations in the stencil; and

e. hardening the binder.

2. A method according to claim I in which the separately movableorienting means comprise a rotatable brush whose axis is parallel withthe axis of the stencil and whose bristles extend to but not beyond theperforations where they are in contact with the product and whichrotates at a speed faster than the stencil in the same direction as thestencil.

3. A method according to claim 1 in which the fibres are precision cutflock fibres.

4. A method according to claim 1 in which the fibres are less than 1.5mm. in length.

5. A method according to claim 1 in which the fibres in the first partof the surface area and the fibres in the second part of the surfacearea lie substantially all at an angle of less than 45 to the plane ofthe surface.

6. A method of making a flocked product comprising a substrate havingbonded to its surface a layer of flocked fibres which are substantiallylinear and which, in different parts of the surface, have differentpredominant non-perpendicular orientations, said method comprising thesteps of:

a. applying fluid binder to the substrate;

b. electrostatically flocking precision cut flock fibres less than 1.5mm. in length onto the fluid binder;

c. laying the fibres in a first part of the surface area in apredominantly non-perpendicular orientation which is at an angle of lessthan 45 to the plane of the surface while maintaining them substantiallylinear by rolling a stencil over and in Contact with the product with norelative movement at the zone of contact between the stencil and theproduct;

d. laying the fibres in a second part of the surface area of the productin a different predominant orientation which is opposite to andsubstantially par allcl to the first orientation and which is such thatthe fibres are substantially all at an angle of less than 45 to thesurface. while maintaining them substantially linear. by rotating in thesame direc tion as. but faster than. the stencil a rotatable brush whichis mounted in the stencil with its axis parallel with the stencil andwhose bristles extend to but not substantially beyond the perforationswhere they are in contact with the product; and

e. hardening the binder.

7. Apparatus comprising a support for sheet material,

a stencil having openings in the surface thereof rotat 8 able in contactwith sheet material carried on the support, and separately movableorienting means contained in the stencil for orienting fibres at theopenings in the surface of the stencil.

8. Apparatus according to claim 7 in which the separately movableorienting means comprise a rotatable brush whose axis is parallel withthe stencil. whose bristles extend to but not substantially beyond theperforations in the stencil surface where they may contact the sheetmaterial on the support, and which is rotatable at a speed faster thanthe stencil in the same direction as the stencil.

9. Apparatus according to claim 7 additionally comprising means forapplying a fluid binder to the sheet material, means for flocking fibresonto the fluid binder before the sheet material contacts the stencil.and means for hardening the binder after the sheet mate rial hascontacted the stencil.

1. A METHOD OF MAKING A FLOCKED PRODUCT COMPRISING A SUBSTRATE HAVING BONDED TO ITS SURFACE A LAYER OF FLOCKED FIBRES WHICH ARE SUBSTANTIALLY LINEAR AND WHICH, IN DIFFERENT PARTS OF THE SURFACE, HAVE DIFFERENT PREDOMINAT NON-PERPENDICULAR ORIENTATIONS, SAID METHOD COMPRISING THE STEPS OF: A. APPLYING FLUID BINDER TO THE SURFACE OF THE SUBSTRATE, B. FLOCKING FIBERS ONTO THE FLUID BINDER, C. LAYING THE FLOCKED FIBRES IN A FIRST PART OF THE AREA OF THE SURFACE IN A PREDOMINANT NON-PREPENDICULAR DIRECTION WHILE MAINTANING THEM SUBSTATIALLY LINEAR BY ROLLING A STENCIL HAVING PERFORATIONS IN THE PERIPHERA SURFACE THEREOF OVER AND IN CONTACT WITH THE PRODUCT WITH NO RELATIVE MOVEMENT AT THE ZONE OF CONTACT BETWEEN THE STENCIL AND THE PRODUCT,
 2. A method according to claim 1 in which the separately movable orienting means comprise a rotatable brush whose axis is parallel with the axis of the stencil and whose bristles extend to but not beyond the perforations where they are in contact with the product and which rotates at a speed faster than the stencil in the same direction as the stencil.
 3. A method according to claim 1 in which the fibres are precision cut flock fibres.
 4. A method according to claim 1 in which the fibres are less than 1.5 mm. in length.
 5. A method according to claim 1 in which the fibres in the first part of the surface area and the fibres in the second part of the surface area lie substantially all at an angle of less than 45* to the plane of the surface.
 6. A method of making a flocked product comprising a substrate having bonded to its surface a layer of flocked fibres which are substantially linear and which, in different parts of the surface, have different predominant non-perpendicular orientations, said method comprising the steps of: a. applying fluid binder to the substrate; b. electrostatically flocking precision cut flock fibres less than 1.5 mm. in length onto the fluid binder; c. laying the fibres in a first part of the surface area in a predominantly non-perpendicular orientation which is at an angle of less than 45* to the plane of the surface while maintaining them substantially linear by rolling a stencil over and in contact with the product with no relative movement at the zone of contact between the stencil and the product; d. laying the fibres in a second part of the surface area of the product in a different predominant orientation which is opposite to and substantially parallel to the first orientation and which is such that the fibres are substantially all at an angle of less than 45* to the surface, while maintaining them substantially linear, by rotating in the same direction as, but faster than, the stencil a rotatable brush which is mounted in the stencil with its axis parallel with the stencil and whose bristles extend to but not substantially beyond the perforations where they are in contact with the product; and e. hardening the binder.
 7. Apparatus comprising a support for sheet material, a stencil having openings in the surface thereof rotatable in contact with sheet material carried on the support, and separately movable orienting means contained in the stencil for orienting fibres at the openings in the surface of the stencil.
 8. Apparatus according to claim 7 in which the separately movable orienting means comprise a rotatable brush whose axis is parallel with the stencil, whose bristles extend to but not substantially beyond the perforations in the stencil surface where they may contact the sheet material on the support, and which is rotatable at a speed faster than the stencil in the same direction as the stencil.
 9. Apparatus according to claim 7 additionally comprising means for applying a fluid binder to the sheet material, means for flocking fibres onto the fluid binder before the sheet material contacts the stencil, and means for hardening the binder after the sheet material has contacted the stencil. 